NASA Student Launch PDR Report

Transcription

1 NASA Student Launch PDR Report Prepared for NASA by Boy Scout Troop 17 Student Launch Team Boy Scout Troop Watercrest Drive Charlottesville, VA Page: 1 of 81

2 Date Revision Remarks Nov 2, Initial Document NASA Student Launch PDR Report Boy Scout Troop 17 Page 2 of 81

3 TABLE OF CONTENTS 1 SUMMARY OF PDR REPORT TEAM SUMMARY LAUNCH VEHICLE SUMMARY PAYLOAD SUMMARY: ANALYZING THERMAL INSULATION PERFORMANCE OF AEROGEL THIN FILMS TEAM CONTACTS TEAM STRUCTURE AND MEMBERS TRIPOLI AND NAR ASSISTANCE CHANGES MADE SINCE THE PROPOSAL VEHICLE CRITERIA OVERVIEW MISSION STATEMENT MISSION SUCCESS CRITERIA DESIGN ALTERNATIVE EVALAUTION Profiles Altitude Control Compartmentalization Flight Stability Launch stability Motor Retention Tracking Leading Design RECOVERY SUBSYSTEM Components and Alternatives Parachutes MISSION PERFORMANCE PREDICTIONS Flight Profile Simulations and Altitude Predictions Center of Pressure and Center of Gravity Landing Predictions Drift Predictions SAFETY INTRODUCTION COMPLIANCE WITH BOY SCOUT SAFETY REGULATIONS SAFETY BRIEFINGS NAR/TRA MENTOR PROCEDURES FOR TEAM MENTOR TO PERFORM PROCEDURES FOR TRA/NAR PERSONNEL TO PERFORM HANDLING OF HAZARDOUS MATERIALS COMPLIANCE WITH THE LAW SAFETY REGULATIONS LINKS: TEAM MEMBER AGREEMENT TO COMPLY WITH SAFETY RULES PRELIMINARY CHECK LISTS Final Assembly Launch Procedures NASA Student Launch PDR Report Boy Scout Troop 17 Page 3 of 81

4 4.12 RISK DEFINITIONS PRELIMINARY PERSONNEL HAZARD ANALYSIS PRELIMINARY LAUNCH VEHICLE FAILURE MODES AND EFFECTS ANALYSIS Ignition Stable Powered Flight Recovery - Drogue Deployment Recovery - Main Deployment Landing Payload Electronics ENVIRONMENTAL RISKS Environmental Impacts on Rocket Rocket s Impacts on Environment PROJECT RISKS PAYLOAD CRITERIA OVERVIEW AEROGEL COATING MEASUREMENT SYSTEM PAYLOAD DESIGN ALTERNATIVES PROJECT PLAN REQUIREMENTS COMPLIANCE Minimum Verification Plans EDUCATIONAL ENGAGEMENT NASA s Mission SLT17 Mission Educational Engagement Plan Educational Engagement Activity Reporting Risk & Mitigation Plan Additional Consideration points Cub Scout Packs Boy s Life Magazine Charlottesville Mini Maker Faire Collaborative Educational Events with Other Nearby SL Teams PROJECT SCHEDULE PROJECT BUDGET Overview Rocket Expense Travel Expense Budget Detail Fundraising Plan NASA Student Launch PDR Report Boy Scout Troop 17 Page 4 of 81

5 1 Summary of PDR Report 1.1 Team Summary The name of our team is SLT17 (Student Launch, Troop 17). We represent Troop 17 of the Boy Scouts of America. SLT Watercrest Drive Charlottesville, VA The team s adult advisor is Steve Yates, NAR (NAR L1 certified) and the team s adult Mentor is Ben Russell, an active Tripoli member in good standing, and Tripoli L3 certified. 1.2 Launch Vehicle Summary Length: 79.1 Body Diameter: 4.25 Weight Without Motor: 15. pounds Weight With Motor: 19.3 pounds Motor Choice: Loki K527 Recovery System: Dual deployment, with 2 drogue and 6 main parachutes Construction Method: Modified COTS, based on Madcow Formula 98 kit 1.3 Payload Summary: Analyzing Thermal Insulation Performance of Aerogel Thin Films The purpose of the experiment is to research the insulation properties of aerogel thin films. Our science payload will consist of three chambers around the motor mount that are separated by the fins. The heat generated by the motor during flight will be the heat source, and the goal is to measure the effectiveness of an aerogel thin film insulation consisting of finely powdered aerogel mixed into paint in isolating the heat generated by the motor during flight. Aerogel powder of varying particle sizes will be mixed with paint, and applied to the outside motor mount. A different formulation of aerogel+paint will be applied to each of the three chambers to study the performance of the different formulations. Each chamber will have a temperature sensor inside it, and the sensors will be connected to the analog inputs of an Arduino Uno, which will serve as a multi-channel temperature-logging unit. The Arduino will also be expanded using an SD card shield board to provide non-volatile flash memory storage that can retain the flight data and also allow it to be uploaded to a computer for post-flight data analysis. The advantage of using SD versus volatile memory is that even if power is lost (for example, if rocket recovery takes longer than planned), the loss of battery power for the Arduino will not result in the loss of fight data. Of the three chambers, one will be a control, with no aerogel paint at all, in order to collect data for the insulated case. One chamber will have small particle sizes, and the last chamber will have large particle sizes. Temperatures will be samples as close in time as possible, and the temperature data will be stored by the Arduino on the SD During post-flight data analysis, we will observe any differences in the temperatures and draw conclusions from that. NASA Student Launch PDR Report Boy Scout Troop 17 Page 5 of 81

6 1.4 Team Contacts The following is contact information for SLT17 youth and adult leadership. To comply with BSA Youth Protection and Online Safety requirements, youth are referred to in this document (and all other public documents) by first name only and youth contact information is not provided here, but will be provided to NASA directly in a private communication. Name Title Phone Steve Yates Troop 17 STEM steveyates@embarqmail.com Chair Hunter SLT17 Team Leader Roman SLT17 Safety Officer All deliverables during the period of performance for the program, other than this proposal, will be delivered to NASA and made publicly available via the team s website, which will be a new section of the existing Troop 17 website: Team Structure and Members The following table and organization chart provide details on team members, their roles, and team structure. Name Role Team Hunter Team Leader Beau Airframe Rocket Cole Recovery Rocket Seamus Flight ops, Analysis, Rocket Testing Caleb Payload Kartik Payload Victor Website/ Social Media Creative Bryce Rocket Artwork Creative Shrey Education and Outreach Creative Mac Finance Business Keaton Development Business Roman Safety Officer Safety NASA Student Launch PDR Report Boy Scout Troop 17 Page 6 of 81

7 Boy Scout Troop Student Launch Team Organizational Chart Team Leader Hunter Rocket Payload Creative Business Safety Beau Airframe Cole Recovery Shay Analysis, Testing, and Flight Ops Caleb Kartik Victor Website, Social Media, Artwork Bryce Rocket Artwork Shrey Education and Outreach Mac Finance Keaton - Development Roman 1.6 Tripoli and NAR Assistance Tripoli Central Virginia #25 has graciously offered its assistance to SLT17. This Tripoli prefecture is located very close to us, and is providing assistance including an expert mentor, design and documentation review, and what is probably the best high-power launch site in Virginia which is located near Culpeper, VA and typically has an FAA waiver of 15, feet AGL. Tripoli #25 is experienced working with SL teams, and they are also supplying a mentor and similar assistance to Boy Scout Troop 295, a fellow TARC finalist located in Woodbridge, VA that is also submitting a proposal for SL this year. Troop 17 s TARC team has conducted launches with Tripoli #25 for 1 years. The prefecture also sponsors the Battle of the Rockets which is a well-established collegelevel rocketry challenge that is similar in some ways to SL. We also will be working with the Northern Virginia Association of Rocketry (NOVAAR), NAR Section 25. NOVAAR is the sponsoring NAR section for the TARC finals, and they offer a wealth of mentoring as well as a backup launch site near Warrenton, VA with a 5, foot AGL FAA waiver (suitable for the subscale flight, if our primary site is unavailable). Lastly, the Valley Aerospace Team (VAST) operates our second backup launch site near Monterey, VA, which typically has a 1, foot AGL FAA waiver. NASA Student Launch PDR Report Boy Scout Troop 17 Page 7 of 81

8 2 Changes Made Since the Proposal We lengthened the rocket because we needed to accommodate the experiment. This involved creating a new avionics bay directly forward from the fin can section to house the Arduino and its battery which are used as the temperature logger. 3 Vehicle Criteria 3.1 Overview Recognizing that SLT17 is composed mainly of middle school students, our approach is to de-risk the rocket design and construction to the greatest extent possible. This allows us to maximize safety and our chances of success. Our approach to doing this is to base our launch vehicle on a commercially-available high-power rocket kit and modify it to carry the science payload and to meet other SL requirements (like 2. calibers of static margin). Basing the launch vehicle on a kit provides an example of a successful dual deployment high power rocket, and it also helps avoid possible issues with parts availability since the parts all come together. We feel our approach even follows NASA s example of re-using existing technology for new missions, where possible. This approach is followed extensively in SLS, with the re-use of many designs and technologies developed for the Space Shuttle, adapting them as necessary. We recognize that basing our design on a modified commercial off-the-shelf (modified COTS) kit does not reduce the need for design simulation, analysis, testing, or safety actives. We will undertake all these activities just like we had a scratch-designed rocket. The projected launch vehicle is based on a modified Mad Cow Formula 98 with dual deployment. One advantage of this kit is that Mad Cow sells a subscale version that we can use as our sub-scale rocket: the fiberglass Mad Cow Formula 75. These kits were selected because they meet all of our mission requirements as shown in preliminary Rocket simulations and because they can be modified to carry our payload. Specific factors include: they are easy to build, they are strong, and they have been already been flight tested (though we are not reducing our testing or analysis). These rockets will be built using the RocketPoxy structural epoxy. All appropriate PPE will be used during the construction of the rockets. These include but not limited to: protective eye wear, protective outer clothing, vented space, and the use of nitrile gloves. Additionally, dust masks will be used during any sanding. Good ventilation will be used when using solvents (acetone), epoxies, and paints. 3.2 Mission Statement The Troop 17 Student Launch team will build a rocket capable of reaching an altitude of 528 feet above ground level while carrying our payload. The rocket will be recovered using a redundant dual deployment system, and will transmit its position both before and after the flight to the ground station via a GPS tracking system. NASA Student Launch PDR Report Boy Scout Troop 17 Page 8 of 81

9 3.3 Mission Success Criteria Our mission will be successful as if the flight is safe, the science experiment returns useful data, and the launch vehicle attains an altitude close to the 528 feet AGL goal. Finally, the rocket s recovery system must operate correctly and successfully bring the rocket safely to the ground. 3.4 Design Alternative Evalaution Profiles We have to consider alternatives for the profile of the rocket, the number of sections from the body, and the nosecone. There are two types of profiles: Standard and nonstandard. A standard profile is where the entire body of the rocket has the same diameter, whereas a non-standard one has sections that are of different diameters. Profile Pros Cons Standard Nonstandard Is easy to design, model, and build, and has normal aerodynamics Possibly lower weight and more interior space None Harder to build design and model for simulation Requires diameter transition pieces The body sections are the separable parts of the body Number of sections Less than 3 Advantages Less places for the rocket to accidentally separate Disadvantages Not enough sections to hold both parachutes without additional work required on the recovery system 3 No extra work required for the recovery system Takes more effort to construct the body More than 3 none Requires even more effort to construct the body There are different types of nose cones; Ogive, which have a profile like a parabola but ends in a steep point, parabolic, which is like a regular cone but has a profile of a parabola with a more rounded end, and cone, which is simply a cone. Nose Cone Type Ogive Advantages Commercially available for our body tube size and is the cone type used in our kit Disadvantages Slightly higher drag NASA Student Launch PDR Report Boy Scout Troop 17 Page 9 of 81

10 Parabolic Slightly lower drag Not available for use with our body tube and kit Cone Lower drag when encountering higher speeds Not available for use with our body tube and kit Altitude Control Altitude Control Advantages Disadvantages Air Brakes Precise control of vehicle s altitude Can compensate for motor manufacturing variations or changing launch conditions Ballasting Easy to manufacture Not as expensive Less possibility of failure Expensive Need electronic controls Difficult to manufacture and install Adds additional failure modes that would be safety critical to the rocket s flight Not as precise control of altitude Ballast placement can impact static margin Compartmentalization Due to the black powder charges for separation of the launch vehicle, we need bulkheads to protect areas of the rocket that are more sensitive like the electronics and experiment. Some of the bulkheads will also be used to mount onto the recovery harness. There are different materials to use for the bulkheads; plywood, fiberglass, and aluminum. Material Advantages Disadvantages Plywood Lighter Cheaper Easier to use than either materials Fiberglass Easier to use than aluminum Stronger than Plywood Lighter than aluminum Aluminum Stronger than either material Not as strong as the other materials Not as strong as aluminum More expensive than plywood Very difficult to work with Much more expensive than either material Flight Stability Two main points that will determine the launch vehicle s stability are the center of gravity and the center of pressure. The center of pressure is where aerodynamic forces are centered and is NASA Student Launch PDR Report Boy Scout Troop 17 Page 1 of 81

11 determined by the design and location of the fins. The center of gravity location is the balance point of the rocket and is determined by the placement and weight distribution of all of the components making up the launch vehicle. Obviously, the center of gravity location will vary during flight based on the lightening of the motor due to propellant combustion. Fin design options that will determine our launch vehicle s stability include the shape, size, placement, number, and material. Fin Shape Advantages Disadvantages Elliptical Produce less drag Difficult to manufacture Trapezoidal Easy to design, manufacture, and attach Higher drag than elliptical fins Number of Fins Advantages Disadvantages 3 Less weight and drag Less likely to be made unstable by high winds Less time spent into manufacturing and attachment of fins None 4 None More weight and drag More time spent on manufacturing and attachment of fins 4+ Looks cool More weight and drag More time spent on manufacturing and attachment of fins Mounting of Fins Through The Wall Advantages Strong attachment of fins and strengthens the motor mount too. Disadvantages More difficult to attach Exterior Easy to attach Not strong, can shear off easily, does not reinforce motor mount like TTW Fin Material Advantages Disadvantages Plywood Cheaper than Fiberglass or Carbon Not very strong NASA Student Launch PDR Report Boy Scout Troop 17 Page 11 of 81

12 fiber Light weight Stronger than balsa wood Balsa Wood Cheapest Lightest in terms of weight Fiberglass Stronger than both types of woods listed Cheaper than Carbon Fiber Very Weak, not suitable for high power rockets More expensive and harder to work with than wood Carbon Fiber Strongest material listed Most expensive and hardest to work with Launch stability The initial launch stability is determined by the rail system, and depends on whether sufficient speed can be attained at rail exit for sufficient aerodynamic forces to keep the rocket stable. We will discuss the exit velocity under section 4.3. Attachment type Advantages Disadvantages Rail Buttons Attached better More aerodynamic Harder to attach Launch Guides Easier to attach More weakly attached Less aerodynamic Motor Retention The motor retention system will include 2 parts which will keep the motor securely in the rocket during all phases of flight, which is required for a safe flight. Motor Retention Advantages Disadvantages Plate Retainer None Not commercially available in correct size Screw-on Retainer Commercially Available in correct size for engine None Engine Hook None Not commercially available in correct size NASA Student Launch PDR Report Boy Scout Troop 17 Page 12 of 81

13 3.4.7 Tracking For the tracking system, it is important to decide whether to use a commercially available, custom tracking system, or GPS. Type of Tracking Advantages Disadvantages Commercially available tracking Custom tracking Easy to use and setup reliable Can transmit more data than just the position of the rocket Probably less expensive Limited by the data it is designed to sent Probably will be more expensive Less reliable More work involved in setting up Weighs more Has a greater chance of intersystem interference GPS More accurate Requires an additional sensor and an external receiver Leading Design System Subsystem Choice Reason(s) Airframe Profile Single Simplicity, performance Body Sections Three Simplicity Nose Cone Ogive Commercial availability Altitude Challenge Altitude Control Ballast Simplicity, reduced complexity Compartmentalization Bulkhead Material Metal Strength Flight Stability Fin Shape Trapezoidal Ease of fabrication Number of Fins 3 Reduced drag Mounting of Fins TTW Strength Fin Material Fiberglass Commercial availability, ease of construction Launch Stability Rail Attachment Buttons, 1515 Commercial availability, strength NASA Student Launch PDR Report Boy Scout Troop 17 Page 13 of 81

14 Motor Retention Motor Retention Aeropak Commercial availability, strength Centering Rings Fiberglass Commercial availability, strength Centering Rings Material Fiberglass Commercial availability, strength Tracking Commercial or Custom Tracking Commercial Accuracy of tracking Position Detection GPS Accuracy of tracking 3.5 Recovery Subsystem Components and Alternatives The primary components to the recovery system are the main and drogue parachutes, the recovery harnesses, and the avionics. Parachute Material Pros Cons Rip Stop Nylon Strong Used within the hobby UV resistant Commercially available Has a high CD Sensitive to heat Kevlar Significantly higher strength than Nylon. Does not melt or burn. Abrasion resistant. Has a low CD Abrasive material to handle. Recovery Harness Material Nylon Pros High strength. Commonly available for purchase. Cons Low heat tolerance NASA Student Launch PDR Report Boy Scout Troop 17 Page 14 of 81

15 Kevlar Stronger than Nylon. Does not melt or burn. Abrasion resistant. Abrasive material to handle. Mounting Points Forged Eye Bolts Pros Only require one hole in centering rings or bulkheads. Cons Weaker attachment. Can be detached by a spinning section U-bolts Stronger attachment. Cannot be detached by a spinning section Require two holes in centering rings or bulkheads. Recovery Harness Pros Cons Attachment Permanent Minimizes points of failure. Rocket cannot be separated into sections Quick links The rocket can be separated into sections. Can be forgotten. Avionics Barometric altimeter Pros Proven technology Easy to configure Less expensive than a flight computer Cons Vent holes must be sized correctly. Flight computer Proven technology Better data collection Complicated which can lead to configuration errors More expensive. NASA Student Launch PDR Report Boy Scout Troop 17 Page 15 of 81

16 Ejection Method 4F Black powder Pros Proven technology Less expensive. Cons Must be contained Must be handled with care Requires the recovery gear to be protected from hot ejection gases. CO2 Proven technology Less dangerous. Doesn t require protecting the recovery harness and chutes from hot eject gases. More complex to use Higher weight. Larger. More points of failure. Expensive Parachutes Based on the current design, it is estimated that a 2 in Sky Angle Classic drogue parachute and a 6 in Sky Angle Classic main parachute will support a safe descent. Using these recovery chutes, the highest kinetic energy of any section of the launch vehicle at landing is under 55 ft-lbs Leading Design \ System Choice(s) Reason(s) Parachute material Recovery harness material Rip Stop Nylon Rip Stop Nylon parachutes are readily available. Kevlar Kevlar is strong enough to endure the forces involved in with the recovery system with enough of a safety margin. Mounting points U-bolts The additional point of attachment that each U-bolt provides makes them less likely to separate, which makes the recovery system safer. Recovery harness attachment Quick links and swivels Quick links will be used to attach the recovery harnesses to the launch vehicle so that the sections of the launch vehicle can be separated for transport. Swivels will be used to attach the recovery harnesses to the parachutes to prevent tangling the shroud lines. Avionics Barometric altimeter At least one of the altimeters in the rocket is required to be barometric, and it will be simpler to use a barometric altimeter as the secondary one as well. NASA Student Launch PDR Report Boy Scout Troop 17 Page 16 of 81

17 Ejection method Black powder Black powder will be simpler to use than CO2. The recovery system has an avionics bay in the central section of the rocket which will house the altimeters, ejection canisters and attachment points for the recovery harnesses. The Kevlar recovery harnesses are 25 ft. long with a loop at each end for attachment to the recovery u-bolts via the quick-links. The apogee recovery harness is attached to the booster and the aft end of the payload bay. The main recovery harness is attached to the forward section of the payload bay and the nose cone Plan for Redundancy The avionics bay will contain two completely independent altimeters, each of which will have its own battery and be connected to its own pair of ejection canisters. The RRC3 is the primary altimeter and the RRC2 is the backup altimeter. The RRC3 will fire its apogee at apogee followed by the RRC2 firing its apogee charge one second after apogee. The RRC3 will fire the main charge at 75 feet followed by the RRC2 backup charge at 55 feet. The apogee and main back up charges will be 5% larger than the apogee and main charges. 3.6 Mission Performance Predictions The mission performance predictions were made by creating a model of the current design of the rocket by running simulations in Rockets Flight Profile Simulations and Altitude Predictions Conditions were chosen to reflect the likely conditions of the launch site at Huntsville. Condition Value Altitude above sea level 68 feet Latitude, Longitude Temperature Wind Speed Pressure 34.7 degrees, degrees 7 degrees Fahrenheit mph 1.13 bar The charts below show the results of our simulations for the K527. The rocket leaves the rail with a velocity of 67.9 ft/sec reaching an apogee of 5,183 ft. At apogee the RRC3 fires the drogue cute. At 75 ft, the RRC3 fires the main charge deploying the main chute. The rocket lands with a landing speed of 19.6 ft/sec. NASA Student Launch PDR Report Boy Scout Troop 17 Page 17 of 81

18 NASA Student Launch PDR Report Boy Scout Troop 17 Page 18 of 81

19 3.6.2 Center of Pressure and Center of Gravity The Center of Pressure (CP) and the Center of Gravity (CG) were determined using Rockets. The CG is 52.5 in from the tip of the nosecone. The CP is in from the tip of the nose cone at Mach.3. The static stability margin without the motor is 3.43 calibers. The static stability with the motor is 2.18 calibers. The static stability margin after burnout is 2.8 calibers Landing Predictions The kinetic energy was calculated using Equation 4.1 where m is the mass of the rocket and v is its velocity. #$ 2!"= (4.1) Section Velocity (ft/s) Weight (lbs) Kinetic Energy (ft-lbs) Booster Payload Nose cone Energy at Landing NASA Student Launch PDR Report Boy Scout Troop 17 Page 19 of 81

20 3.6.4 Drift Predictions Wind Speed Lateral Drift (ft) Safety 4.1 Introduction Priority one for SLT17 is safety. Priorities 2 and 3 are also safety. Safety is not a separate function, or something to be added after the fact. SLT17 is firmly committed to the fact that safety is the foundation of everything we do, and safety is THE primary mission goal that s even more important than the science or flight objectives. Without safety, there can be no science, so safety is the cornerstone of the team. As previously discussed, we have structured the team to highlight this founding principle. 4.2 Compliance with Boy Scout Safety Regulations Since we are a part of a Boy Scouts of America unit, SLT17 is committed to fully complying with all safety regulations and guidelines as set forth by the Boy Scouts of America National Council. These BSA regulations include the following: Youth Protection ( Cyber Protection ( Youth use of power tools ( This regulation states that youth under the age 14 cannot use power tools at all. Youth between 14 and 18 can only use small handheld sanders, drills, electric screwdrivers, and similar handheld tools. Only adults 18 and older can use power saws. Transportation ( Use of chemicals ( Adult leader training requirements applicable to SLT17 s activities We feel that the BSA safety guidelines are an advantage to SLT17, as they address many underlying issues of personal safety, online safety, and youth protection in a clear and coherent fashion. This contributes to our culture of safety. The team s designated Safety Officer will oversee that all rules and regulations are followed at all times by all members of the team. The Safety Officer will brief all team members on the NASA Student Launch PDR Report Boy Scout Troop 17 Page 2 of 81

21 procedures outlined in the Safety Plan. Also, the NAR/TRA mentor and Safety Officer shall oversee launch operations and motor handling. The NAR/TRA mentor will be the official owner of the rocket for insurance purposes, and they will be the purchaser and user of rocket motors and black powder ejection charges for compliance with relevant laws and regulations. Safety briefings conducted by the Safety Officer will utilize Safety Data Sheets and will come before every activity that requires tools and/or hazardous materials, as well as before all launches. Team members that are late will have to be briefed before they are allowed to begin work on the project. On launch days Flight, Post-Flight checklist and Safety Data Sheets will be handed out and reviewed to ensure the safety of the team members as well the general public. All team members will follow instructions given by NAR/TRA mentor, team leader and/or safety officer. All launches will be conducted in full compliance with all NAR and TRA Safety Code requirements. The main facility that the team will utilize when fabricating the rocket is space at ADI Engineering building in Charlottesville Virginia. All members of the team will have to follow the BSA Guidelines that all youth under the age of 14 cannot use power tools (see section 1.4.1). Scouts over the age 14 will be assigned with the cutting and modify of the rocket. 4.3 Safety Briefings The Safety Officer will be responsible for briefing the team of any possible risks that could occur throughout designing/build process, as well as before each launch. During the briefing, the Safety Officer will inform the team of all necessary procedures to avoid risks or hazards. The Safety Officer will regularly brief team members about these risks in order to create a safe environment. The Safety Officer will also be responsible for informing the team of any laws and regulations that may apply set by the NAR/TRA, including NFPA 1122 (code for Model rocketry) and NFPA 1127 (code for high power rocketry). 4.4 NAR/TRA Mentor Ben Russell has agreed to mentor our team and accompany our team to all launches and Launch Week in Huntsville in April 218. He is a certified Level 3 with the TRA and NAR. His duties will include the purchase, storage, transportation and installation of rocket motors and black powder for ejection charges. Mr. Russell is already actively engaged, and has helped the team tremendously already during the proposal stage. Mr. Russell will be advising the team during design and construction, and during the handling of hazardous or restricted materials. He will also brief the team on launch safety and protocol prior to launch. 4.5 Procedures for Team Mentor to Perform The team mentor shall maintain the proper certification required for the motor impulse used in the launch vehicle. The mentor shall have completed at least two flights in the proper flight class prior to PDR. The TRA certified mentor will purchase, store, and transport rocket motors, black powder, and electric matches. The mentor will be the owner of record for the rocket for TRA/NAR insurance purposes. The Safety Officer and mentor will work together to choose a location where the motor will not be damaged and is at least 25 feet away from any heat sources or flammable NASA Student Launch PDR Report Boy Scout Troop 17 Page 21 of 81

22 liquids. The motor shall be transported separately from the rest of the rocket. During transportation the motor will be protected to prevent any damage. 4.6 Procedures for TRA/NAR Personnel to Perform The Safety Officer will work in conjunction with TRA/NAR personnel and the mentor to ensure that the team complies with the TRA/NAR High Power Safety Codes. The Safety Officer, mentor, and TRA/NAR personnel shall ensure that before launch all conditions are met for a safe launch. The Range Safety Officer (RSO) shall arm the launch system, and will ensure all members and spectators are not within 1 feet of the rocket. The RSO shall count down from five before launch; if the vehicle does not launch, the RSO shall disarm the system and wait 6 seconds before investigating. TRA/NAR personnel along with the safety officer shall ensure no one attempts to catch the rocket on return or remove it from a dangerous location such as a power line. 4.7 Handling of Hazardous Materials Some of the materials to be used will require extreme caution and care. Team members will be reminded of the safety rules based on which portion of the project they are working on by Safety Data Sheets. The materials include but are not limited to fiberglass, black powder, epoxies and other adhesives, powdered aerogel, and rocket motors. The Safety Officer will be tasked with designing protocols for handling, storing, and disposing of these materials. The Safety Officer will be engaged before the purchase of any materials, to make certain that the existing Safety Plan is adequate to address any new safety issues, to proactively identify and acquire any Personal Protective Equipment (PPE) needed, and to collect and maintain all MSDS s and other safety information. Also, the Safety Officer will be responsible for briefing all team members on protocols and regulations for the use of all materials. As fiberglass will be a primary hazard all team members that are working with this airframe material will be required to properly use PPE such as safety goggles and dust masks at all time when sanding, cutting, and painting to prevent dust from get into their eyes or lungs. Since we are using Aerogel in a power form as part of the payload, team members will be required to wear the proper PPE. Also, the proper clothing will be worn, including long sleeve shirt, jeans and gloves, to prevent injury to the legs or arms from sharp objects. The Safety Officer shall brief team members on any other hazards associated with materials used in the rocket or the science payload. The Team will follow all of the BSA regulations as well those stated in the Policy on the Storage, Handling, and Use of Chemical Fuels and Equipment. 4.8 Compliance with the Law A mandatory team briefing will be done by the Safety Officer along with NAR/TRA mentor reviewing all guidelines and regulations upon proposal acceptance by NASA. BSA regulations will be followed at all times. Other relevant laws and regulations that the Safety Officer will educate all team members on that the team will be required to follows at all times are Federal Aviation Regulations 14 CFR, Subchapter F, Part 11, Subpart C; Amateur Rockets, Code of Federal NASA Student Launch PDR Report Boy Scout Troop 17 Page 22 of 81

23 Regulation 27 Part 55: Commerce in Explosives; and fire prevention, NFPA 1127 Code for High Power Rocket Motors. 4.9 Safety Regulations Links: BSA Safety Guide: BSA Age Guidelines For Tools : BSA Policy on the Storage, Handling, and Use of Chemical Fuels and Equipment : Federal Aviation Regulations 14 CFR, Subchapter F, Part 11, Subpart C: Amateur Rockets, Code of Federal Regulation 27 Part 55 Commerce in Explosives: NFPA 1127 Code for High Power Rocket Motors: MSDS for the Aerogels: EN.pdf\ MSDS for Rocketpoxy: MSDS for Acetone: Team Member Agreement to Comply with Safety Rules All team members have signed a Safety Agreement to abide by the regulations discussed as well as the following safety regulations: Range safety inspections of each rocket before it is flown. Each team shall comply with the determination of the safety inspection or may be removed from the program. The Range Safety Officer has the final say on all rocket safety issues. Therefore, the Range Safety Officer has the right to deny the launch of any rocket for safety reasons. Any team that does not comply with the safety requirements will not be allowed to launch their rocket. The Safety Agreement will also state that any violation of safety protocols can result with dismissal from the Team with no warnings. NASA Student Launch PDR Report Boy Scout Troop 17 Page 23 of 81

24 4.11 Preliminary Check Lists SLT17 will utilize checklists during final assembly and flight of our rocket. This will assure we consistently apply best practices and consistent safety controls during flight operations every time Final Assembly Check airframe for damage Check payload Wiring properly in place No damage Motor and flywheel secured Check motor casing for damage Check motor mount Check recovery system Recovery harness connected to drogue chute Recovery harness connected to main parachute Recovery harness between lower section and central section Recovery harness between upper section and central section Avionics bay Altimeters in place and secured Batteries in place, plugged in, and secured Ejection charges in place Electric matches threaded to ejection charges Parachute protectors between ejection charges and parachutes in place Main parachute checked for damage/imperfections NASA Student Launch PDR Report Boy Scout Troop 17 Page 24 of 81

25 Drogue parachute checked for damage/imperfections Main parachute properly folded and in place Drogue parachute properly folded in place Attach rocket components with proper fasteners (bolts or shear pins) Check all connections again Insert motor into motor casing Safety Officer Range Safety Officer Launch Procedures Ensure all unnecessary personnel are in a safe location for launch Place rocket on launch rails Have qualified personnel place electronic igniter Have all personnel move to launch positions Check with range safety officer to ensure range is all clear and ready for launch Safety Officer Range Safety Officer 4.12 Risk Definitions The severities and likelihoods of the various risks are given in the Risk Assessment Code (RAC) format from pages 58 and 59 of the Student Launch Handbook. The possible values for severity are: 1 Catastrophic, 2 Critical, 3 Marginal, and 4 Negligible. The possible values for likelihood are: A Frequent, B Probable, C Occasional, D Remote, and E Improbable. The risks below have both a Pre-RAC value and a Post-RAC value. Pre-RAC refers to the combined severity and likelihood before mitigations are put in place, and Post-RAC is after the mitigations have been put in place. 3

26 4.13 Preliminary Personnel Hazard Analysis Our primary risk concern will always be the safety of all personnel involved with the project. The risk team members and the public can take place during both fabrication, launch and flight of the rocket. The secondary component for a successful project completion will be meeting of deadlines. Risk Probability Severity: Effect Prevention Injury during fabrication Low High: Minor to serious injuries including cuts and burns Receiving training in the safe use of all equipment, require PPE to be used at all times, follow BSA safety requirements, and make sure a first aid kit is always present during all team functions. Injury during rocket launch Low High: Minor to serious injury Following all launch safety procedures, such as staying the proper distance away and inspecting launch guide, motor casing, and other parts beforehand, and following all NAR/TRA safety code requirements. Also follow all BSA safety requirements, and make sure a first aid kit is always present during all team functions. Accidental ignition or detonation of material Low High: Possible burns Following safety procedures for the handling of explosive material; ensuring everyone is in a safe location in case of detonation on launch pad. Injury during rocket recovery Low High: Minor burns Follow all recovery safety procedures Motor mount failure Low High: Damage to rocket and potentially observers Testing the motor mount in simulations, static fire tests, and experimental flights. Inspecting as specified by prelaunch checklist 31

27 Hazard Effect Cause Mitigation Pre-RAC Post-RAC Accidental Moderate Improper Black powder will be 3D 3E black powder injury (burns). handling or properly stored and ignition storage of black handled only by our powder. mentor. Power tools Minor to severe Improper use. All team members 2D 2E injury. Distractions involved in the fabrication of the rocket will be briefed on how to safely use all power tools. We will follow BSA regulations on power tool usage. Fiberglass Minor to Fiberglass dust Gloves and masks will 3C 3E moderate on skin, in eyes be worn when working injury. or in lungs. with fiberglass. Any dust will be cleaned up Preliminary Launch Vehicle Failure Modes and Effects Analysis Ignition Failure Engine fails to ignite Potential Effects Recycle/delay of launch. Causes Mitigations Pre-RAC Post-RAC Bad igniter. None. 4C 4C 32

28 Stable Powered Flight Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Rocket goes off Failure to reach Launch rail is Check launch rail 1C 1E course desired altitude. not vertical. direction with post level before launch. Vehicle flies Incorrectly Use ground into crowd. aligned fins or based and in- insufficient flight test to velocity at rail ensure the fins are exit. aligned, assure sufficient rail exit velocity. Rocket lands in Offset CG. Use ballast to the wrong ensure the CG is place. centered. Failure to reach Misaligned Purchase pre-cut sufficient engine/engine components altitude for mount. (using laser recovery cuter) for motor system. mount. 33

29 Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Internal damage Damage to High Ensure all points 2D 2E rocket. acceleration., of failure are Experiment insufficient build strong enough to failure. strength. withstand the Recovery system maximum failure. expected acceleration with a margin of safety. Use liberal epoxy fillets on fins and motor mount. Engine ejects Falling debris. Insufficient Use metal 1D 1E from rocket motor retention screw-type or thrust ring. motor retainer. Damage to Engine mount Ensure the rocket. fails. engine mount is Engine flies into strong enough to crowd. withstand the force from the engine. 34

30 Recovery - Drogue Deployment Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Recovery harness Falling debris. Too much black Repeated tests of 1D 1E breaks powder. the ejection system on the ground. Destruction of rocket. Damaged recovery Inspect the harness. recovery harness Rocket is before launch. moving too fast Choose the at deployment. engine and ballast and program the recovery electronics such that the rocket is moving at a safe velocity when the parachute deploys. 35

31 Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Ejection charge Drogue chute Bad igniter. Redundant 1C 1E doesn't ignite doesn't deploy - Altimeters not igniters and see below. turned on. ejection cups. Altimeters not Follow pre- programmed launch checklist. correctly. Have the mentor, Batteries not RSO, and safety charged. officer inspect Wires come the ejection loose. system before Batteries come launch. loose. Black powder not properly secured before launch. Ejection charge Rocket is Not enough Repeated tests of 1D 1E fires but drogue moving too fast black powder. the ejection chute doesn't for main chute system on the deploy to deploy. ground. Falling debris. Too much Repeated tests of friction. the ejection system on the ground. 36

32 Recovery - Main Deployment Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Recovery harness Falling debris. Too much black Repeated tests of 1D 1E breaks. powder. the ejection system on the ground. Destruction of rocket. Damaged recovery Inspect the harness. recovery harness before launch. Rocket is Choose the size of moving too fast. the drogue chute such that the rocket is moving at a safe velocity when the main parachute deploys. Ejection charge Parachute Bad igniter. Redundant 1C 1E doesn't ignite doesn't deploy - Altimeters not igniters and see below. turned on. ejection cups. Altimeters not Follow pre- programmed launch checklist. correctly. Batteries not charged. Wires come loose. 37

33 Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Batteries come Have the mentor, loose. RSO, and safety Black powder officer inspect not properly the ejection secured before system before launch. launch. Ejection charge Destruction of Not enough Repeated tests of 1D 1E fires but rocket. black powder. the ejection parachute system on the doesn't deploy ground. Falling debris. Too much Repeated tests of friction. the ejection system on the ground Landing Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Rocket hits the Damage to Parachute is too Run simulations 2D 2E ground too hard rocket or small. to ensure the injury to parachute is the people. correct size for the rocket. Rocket lands in Rocket falls on Wind. Don't launch 2C 2D undesirable people. when wind speed high, 4

34 Failure place (e.g. on people, on a car, on a road, in a pond, etc.) Potential Effects Causes Mitigations Pre-RAC Post-RAC angle the launch rail to account for wind. Damage to cars, etc. Damage to rocket. Bad launch angle. Drogue chute too big. Check launch rail angle before launch. Use the smallest possible drogue that will allow safe deployment of the main chute. Electronics destroyed and data lost (rocket lands in pond) Hazards at launch site. Choose suitable launch sites for rocket size Payload Electronics 41

35 Failure Data collection failure (Arduino temperature logger) Potential Effects Payload fails to meet experiment criteria. Causes Mitigations Pre-RAC Post-RAC Programming error. The payload 3C program will be tested on the ground and in test flights; every part of the program will be reviewed by multiple people. 3E 42

36 Failure Potential Effects Tracking system failure. Causes Mitigations Pre-RAC Post-RAC Programming Ground and in flight failure. tests will ensure the Rocket too far transmitter and from receiver. receiver have Interference. sufficient range. 43

37 Failure Potential Effects Causes Mitigations Pre-RAC Post-RAC Physical failure All other Batteries Perform ground 2D 2E payload come loose. tests to find out electronics Wires come how long the failures. loose. batteries will last; Batteries not keep track of how charged long each battery has been used 4.15 Environmental Risks Environmental Impacts on Rocket Hazard Effect Mitigation Pre-RAC Post-RAC Direct sunlight/high Overheating of Assemble and 3D 3E temperatures electronic store rocket in components, shaded area. affecting efficiency. Possible distortion of airframe. Humidity Swelling of Inspect rocket 3D 3E airframe before launch for components. Wet airframe swelling. rocket and Electronics should be electrical sealed to components 44

38 Hazard Effect Mitigation Pre-RAC Post-RAC protect from water. Wind Rocket potentially Check simulations 2C 2E flies off trajectory. and flights for Drifts farther after stability. parachute Minimize time on deployment. main parachute to ensure minimal drift while maintaining safe landing speed Rocket s Impacts on Environment Risk Cause Effect Mitigation Pre-RAC Post-RAC Grass fire Rocket Burnt vegetation. Fire 3D 3E crashes while Potential injury. extinguishers motor is still shall be ready burning. during launch. Scattered Rocket Harmful chemicals See Preliminary 2D 2E rocket breaks and materials Failure Modes components during flight. released into and Effects Recovery environment. Analysis above. system fails. Negative impacts to wildlife and vegetation. 45

39 Risk Cause Effect Mitigation Pre-RAC Post-RAC Harming Animals Potential injury. Inspect launch 2D 2E wildlife wander onto field for launch field. potential wildlife Project Risks Risk Likelihood Impact Mitigation Late completion of reports and presentations Team members dropping out Low High Set early deadlines and have multiple people working on sections in order to ensure completion. Medium High Ensuring all members are able to commit time to the team. Making sure all roles can be filled by someone else if needed. Funding shortages Low Medium Ensure that budget is spent wisely and find sponsors and individual donors to help close gaps. Rocket destroyed during transport, fabrication, or launch. Low High Take proper precautions to reduce risk, including proper storage. Follow all checklists for inspection of rocket and launch procedure. 46

40 Risk Likelihood Impact Mitigation Failure to complete experiment requirement Low High Experimental flights with proof-of-concept rocket as well as scaling of experiment to subscale and final rockets to ensure design works. 47

41 5 Payload Criteria 5.1 Overview The purpose of the experiment is to research the insulation properties of aerogel thin films. Lightweight, easily applied thin film thermal insulation is of great value in space missions, and our experiment will gather data and analyze the effectiveness of aerogel thin films during actual flight conditions. Our science payload will consist of three chambers around the motor mount that are separated by the fins. The heat generated by the motor during flight will be the heat source, and the goal is to measure the effectiveness of an aerogel thin film insulation consisting of finely powdered aerogel mixed into paint in isolating the heat generated by the motor during flight. Aerogel powder of varying particle sizes will be mixed with paint, and applied to the outside motor mount. A different formulation of aerogel+paint will be applied to each of the three chambers to study the performance of the different formulations. Each chamber will have a temperature sensor inside it, and the sensors will be connected to the analog inputs of an Arduino Uno, which will serve as a multi-channel temperature-logging unit. The Arduino will also be expanded using an SD card shield board to provide non-volatile flash memory storage that can retain the flight data and also allow it to be uploaded to a computer for post-flight data analysis. The advantage of using SD versus volatile memory is that even if power is lost (for example, if rocket recovery takes longer than planned), the loss of battery power for the Arduino will not result in the loss of fight data. Of the three chambers, one will be a control, with no aerogel paint at all, in order to collect data for the insulated case. One chamber will have small particle sizes, and the last chamber will have large particle sizes. Temperatures will be samples as close in time as possible, and the temperature data will be stored by the Arduino on the SD During post-flight data analysis, we will observe any differences in the temperatures and draw conclusions from that. 48

42 5.2 Aerogel Coating The objective is to test the difference of the insulation properties between large and small particles of aerogel when mixed with paint. In order to make sure the flight tests will produce meaningful data, we will run an insulation experiment with the aerogel on the ground first to determine the right mixture, particle size, film thickness, and proportions of aerogel and paint to use before attempting it in the rocket. This ground test does not need to use a rocket motor, any heat source would work. We propose to use an electrically generated heat source, such as a heat gun. The aerogel powders we propose to use are readily available from BuyAerogel.com, available as Enova aerogel in the following grades: IC31, which consists of ultrafine particles with diameters ranging from 2 to 4 µm. 1-L bottle is $68. IC311, which consists of fine particles with diameters ranging from 1-7 µm (.1-.7 mm). 1- L bottle is $68. The aerogel mixed with paint is expected to provide some degree of thermal insulation between the rocket motor and the exterior of the motor mount. The diagram below provides some data on coatings made from Enova aerogel and indicates the anticipated thermal conductivity should be between 3 and 5 mw/m K. Since most of the heat produced by the rocket motor will be propelled out the back of the rocket, it is difficult to estimate the temperature increase inside the rocket. Therefore, we will use the three chambers surrounding the motor mount to realize three different experiments. One will be a control chamber that will be coated with plain paint. The other two chambers will be coated with a mixture of paint and one of the two grades of aerogel mentioned above: IC31 or IC311: Need to review safety concerns of handling aerogel particles: Aerogel particles and blankets may generate nuisance dust when handled and so appropriate protective gear such as safety glasses, gloves, and a dust mask are recommended when handling these types of products. For non-silica aerogel materials, the aerogel form is, in general, as safe as the material(s) upon which the aerogel is based, keeping in mind that particulate forms of any material can potentially present respiratory hazards. For more information about a particular 49